While significant progress has been made in laser powder bed fusion (L-PBF) for metal additive manufacturing (AM), there is still limited large scale adoption of this advanced manufacturing techniq

Laser powder bed fusion for metal additive manufacturing: perspectives on recent developments

Aircraft electrification is currently the best alternative to address the rising demand for more air transportation and deal with anticipated economic and environmental impacts. Although the all-electric-aircraft (AEA) concept is not yet a feasible solution, the more-electric aircraft (MEA) is gaining significant attention. Electrical systems either partially or entirely replace the large and inefficient hydraulic, pneumatic, and mechanical conventional aircraft actuating systems. The upgrade could also encompass the propulsion system, as in hybrid- and turbo-electric aircraft. This upgrade reduces the aircraft weight, reduces the usage of pollutant fluids, increases fuel efficiency, reduces carbon emissions, and increases aircraft controllability and reliability. This article reviews various application areas of electric machines in electrified aircraft, such as actuation, taxiing, propulsion, and generation. Moreover, it reviews the main types of currently/to be utilized electric machines and the critically required specifications. Finally, a comparison between the different considered machines and potential future research is discussed.

Review of Electric Machines in More-/Hybrid-/Turbo-Electric Aircraft

Additive manufacturing of magnetic materials

Additive manufacturing of soft magnets for electrical machines—a review

Techniques that use the layer-by-layer manufacturing concept have triggered novel research topics related to the processing of functional magnetic materials (FMMs). In this article, we focus on four FMM classes due to their technical relevance for energy conversion, harvesting, transmission, and sensing/actuation. Permanent magnets, soft magnetic materials, magnetocaloric compounds, and magnetic shape memory alloys are reviewed in terms of functionality and performance limits. Relationships among printing techniques and/or conditions, microstructure and performance are highlighted. Additively manufactured hard magnets are the closest to commercial/industrial application.

Additive manufacturing of soft magnetic materials and components based on laser powder bed fusion (L-PBF) offers new opportunities for soft magnetic core materials in efficient energy converters. For more favorable material compositions like FeSi6.7 (strategy 1) with larger electrical resistivity and close-to-zero magnetostriction a maximum permeability of μmax = 31,000, minimum coercivity of Hc = 16 A/m and hysteresis losses of 0.7 W/kg at 1 T and 50 Hz have been realized. To further reduce eddy current losses significantly, novel topological structures like inner slits (strategy 2) and multilayered structures of alternating layers of electrically insulating material and soft magnetic material (strategy 3) are suggested. Feasibility, functionality and potential of the different strategies (and combinations thereof) are discussed based on first prototypes and supporting simulations. The results are compared to conventional electrical steel and SMC (soft magnetic composites).

Additive manufacturing of soft magnetic materials and components

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Additive manufacturing of soft magnetic materials and components